Avoidance of Drill Cap Formation in CFRP-Titanium Stack Materials by Using Vibration Assisted Drilling with Defined Coupling of the Oscillation
 
More details
Hide details
1
IFT - Institute for Production Engineering and Photonic Technologies, TU Wien, Austria
 
 
Submission date: 2023-04-06
 
 
Final revision date: 2023-05-17
 
 
Acceptance date: 2023-05-17
 
 
Online publication date: 2023-05-22
 
 
Publication date: 2023-06-12
 
 
Corresponding author
Markus Prießnitz   

IFT - Institute for Production Engineering and Photonic Technologies, TU Wien, Austria
 
 
Journal of Machine Engineering 2023;23(2):77-99
 
KEYWORDS
TOPICS
ABSTRACT
Drilling of rivet holes in stacked materials consisting of CFRP and Ti-6Al-4V still represents unique challenges. It is common practice to drill the material layers using one single tool. When exiting the final metallic layer, formation of a drill cap usually leads to undesirable burrs and debris, requiring manual post-processing. In this work, a drilling process to avoid drill caps is presented. This is realized using low frequency high amplitude vibration assisted drilling with defined coupling of the rotational speed and the axial oscillations. Drilling parameters and their impact on the quality of the drilled hole in the metallic layer are also investigated. It is found that drill tip geometries and process parameters need to be tuned together to achieve a stable and repeatable process for drill cap avoidance. A highly sensorized experimental setup with multi-sensor systems including high-speed and thermal imaging was used for process evaluation.
 
REFERENCES (33)
1.
Statista, Use of materials in aircraft design 2014, https://www.statista.com/stati...- in-aircraft-design/?locale=en (accessed Mar. 03, 2023).
 
2.
BREUER U.P., 2016, Commercial Aircraft Composite Technology, New York, NY: Springer Berlin Heidelberg.
 
3.
MEMON D.O., 2023. Confusing Quantification: How Many Parts Does an Airliner Have?, Simple Flying, https://simpleflying.com/airli... (accessed Apr. 06, 2023).
 
4.
LIU D., TANG Y., CONG W.L., 2012, A Review of Mechanical Drilling for Composite Laminates, Compos. Struct., 94/4, 1265–1279, https://doi.org/10.1016/j.comp....
 
5.
ZHU Z. et al., 2018, Evaluation of Novel Tool Geometries in Dry Drilling Aluminium 2024-T351/Titanium Ti6Al4V Stack, J. Mater. Process. Technol., 259, 270–281, https://doi.org/10.1016/j.jmat....
 
6.
PARK K.-H., BEAL A., KIM D.W., KWON P., LANTRIP J., 2011, Tool Wear in Drilling of Composite/Titanium Stacks Using Carbide and Polycrystalline Diamond Tools, Wear, 271/11–12, 2826–2835, https://doi.org/10.1016/j.wear....
 
7.
SENTHILKUMAR M., PRABUKARTHI A., KRISHNARAJ V.., 2018, Machining of CFRP/Ti6Al4V Stacks Under Minimal Quantity Lubricating Condition, J. Mech. Sci. Technol., 32/8, 3787–3796, https://doi.org/10.1007/s12206....
 
8.
HASSAN M.H., ABDULLAH J., MAHMUD A.S., SUPRAN A., 2017, Burr Height as Quality Indicator in Single Shot Drilling of Stacked CFRP/Aluminium Composite, Key Eng. Mater., 744, 327–331, https://doi.org/10.4028/www.sc....
 
9.
BRINKSMEIER E., PECAT O., RENTSCH R., 2015, Quantitative Analysis of Chip Extraction in Drilling of Ti6Al4V, CIRP Ann., 64/1, 93–96, https://doi.org/10.1016/j.cirp....
 
10.
NAN C., WU D., GAO Y., MA X., CHEN K., 2015, Influence of Metal Chips on Drilling Quality of Carbon Fiber Reinforced Plastic and Titanium Stacks, IEEE International Conference on Cyber Technology in Automation, Control, and Intelligent Systems (CYBER), Shenyang, China: IEEE, 1204–1209, https://doi.org/10.1109/CYBER.....
 
11.
LAPORTE S., De CASTELBAJAC C., LADONNE M., 2016, Vibration Assisted Drilling on Automated Drilling Units: Challenges, Dynamic Modelization and Prospective Developments, Aerospace Manufacturing and Automated Fastening Conference & Exhibition, SAE, https://doi.org/10.4271/2016-0....
 
12.
MUELLER-HUMMEL P., 2011, New Solutions for one Shot Hand Held and Robot Drilling of CFRP/Titan and -/Aluminium Stack Drilling in H8 Quality for Aerospace Applications, Aerospace Technology Conference and Exposition, https://doi.org/10.4271/2011-0....
 
13.
MUELLER-HUMMEL P., ATARSIA A., WIEMANN A., 2013, One Shot - Dry - Drilling of Composites / Aluminium Hybrid Stacked Materials in IT8 Quality, AeroTech Congress & Exhibition, SAE, https://doi.org/10.4271/2013-0....
 
14.
ASSADI M., MARTIN C., SIEGEL E., MATHIS D., 2013, Body Join Drilling for One-Up-Assembly, SAE Int. J. Aerosp., 6/1, 188–194, https://doi.org/10.4271/2013-0....
 
15.
DEVLIEG R. FEIKERT E., 2008, One-Up Assembly with Robots, SAE Whitepapers, https://www.electroimpact.com/....
 
16.
LAPORTE S., De CASTELBAJAC C., 2012, Major Breakthrough in Multi Material Drilling, Using Low Frequency Axial Vibration Assistance, SAE Int. J. Mater. Manuf., 6/1, 11–18, https://doi.org/10.4271/2012-0....
 
17.
JALLAGEAS J., CHERIF M., J.-Y. K’NEVEZ, CAHUC O., 2013, New Vibration System for Advanced Drilling Composite-Metallic Stacks, SAE Int. J. Mater. Manuf., 7/1, 23–32, https://doi.org/10.4271/2013-0....
 
18.
LONFIER J., DE CASTELBAJAC C., 2014, A Comparison Between Regular and Vibration-Assisted Drilling in CFRP/Ti6Al4V Stack, SAE Int. J. Mater. Manuf., 8/1, 18–26, https://doi.org/10.4271/2014-0....
 
19.
De CASTELBAJAC C., LAPORTE S., LONFIER J., PUVILAND E., 2015, A Global Improvement in Drilling and Countersinking of Multi-Material Stacks with Vibration Assisted Drilling, SAE Int. J. Mater. Manuf., 9/1, 16–23, https://doi.org/10.4271/2015-0....
 
20.
PECAT O., PAULSEN T., KATTHÖFER, P., BRINKSMEIER E., FANGMANN S., 2016, Vibration Assisted Drilling of Aerospace Materials, Aerospace Manufacturing and Automated Fastening Conference & Exhibition, SAE, https://doi.org/10.4271/2016-0....
 
21.
PECAT O., BRINKSMEIER E., 2014, Low Damage Drilling of CFRP/Titanium Compound Materials for Fastening, Procedia CIRP, 13/1–7, https://doi.org/10.1016/j.proc....
 
22.
HUSSEIN R., SADEK A., ELBESTAWI M.A., ATTIA M.H., 2018, Low-Frequency Vibration-Assisted Drilling of Hybrid CFRP/Ti6Al4V Stacked Material, Int. J. Adv. Manuf. Technol., 98/9–12, 2801–2817, https://doi.org/10.1007/s00170....
 
23.
BLEICHER F., WIESINGER G., KUMPF C., FINKELDEI D., BAUMANN C., LECHNER C., 2018, Vibration Assisted Drilling of CFRP/Metal Stacks at Low Frequencies and High Amplitudes, Prod. Eng., 12/2, 289–296, https://doi.org/10.1007/s11740....
 
24.
BAI W., GAO Y., SUN R., 2023, Vibration Assisted Machining: Fundamentals, Modelling and Applications, Singapore, Springer.
 
25.
ZHU Z., SUN X., GUO K., SUN J., LI J., 2022, Recent Advances in Drilling Tool Temperature: A State-of-the-Art Review, Chin. J. Mech. Eng., 35/1, 148, https://doi.org/10.1186/s10033....
 
26.
LTI Motion GMBH, 2016, Documentation LeviSpin Vibrations-Bohrspindel.
 
27.
DEVLIEG R., SITTON K., FEIKERT E., INMAN J., 2002, ONCE (ONe-sided Cell End effector) Robotic Drilling System, Automated Fastening Conference & Exhibition, SAE, https://doi.org/10.4271/2002-0....
 
28.
SONNENBERG V., MEINHARD A., GÜTH S., 2017, Gratminimales Bohren mit VHM-Bohrerkonzepten – ein Werkzeugbenchmark, MM - Maschinenmarkt, [Online], https://www.maschinenmarkt.vog....
 
29.
AMOYAL J., GARBER R., KARAMA M., KASSAHUN M., KOOHI A., 2015, Design of an enhanced FOD inspection system for the aircraft assembly process, Systems and Information Engineering Design Symposium, Charlottesville, VA, USA: IEEE, 142–147, https://doi.org/10.1109/SIEDS.....
 
30.
DORNFELD D., MIN S., 2010, A Review of Burr Formation in Machining, in Burrs - Analysis, Control and Removal, J. C. Aurich and D. Dornfeld, Eds., Berlin, Heidelberg: Springer Berlin Heidelberg, 3–11, [Online], https://doi.org/10.1007/978-3-....
 
31.
FELDSHTEIN E., 2011, The Influence of Machining Conditions on Burr Shapes when Drilling Reach-Through Holes in Difficult-To-Cut Materials, Adv. Manuf. Sci. Technol., 35, 75–83.
 
32.
JAACKS K., 2016, Automated Circumferential Joint Assembly in Aircraft Production - Development and Assessment of a Production Process, Chalmers University of Technology, Gothenburg.
 
33.
REITER M., BLEICHER F., 2019, Affectation of Chip Formation in Single-Lip Deep Hole Drilling at Small Diameters by Application of Low-Frequency Vibration Support, mm sci. j., 2019/04, 3107–3113, https://doi.org/10.17973/mmsj.....
 
 
CITATIONS (1):
1.
Process parameter auto-adaptation strategy for one-up drilling of CFRP/aluminium hybrid stack
Martina Panico, Eva Begemann, Andreas Gebhardt, Felix Hartmann, Tobias Herrmann, Antonio Langella, Luca Boccarusso
The International Journal of Advanced Manufacturing Technology
 
eISSN:2391-8071
ISSN:1895-7595
Journals System - logo
Scroll to top